Rug and the method of making the same



Oct. 17, 1944. w. 1-. CASE 2,360,398

RUG AND THE METHOD OF MAKING THE SAME Filed March 27, 1944 INVENTOR.

I J Cad,

MMQ MWM Patented Oct. 17, 1944 RUG AND THE METHOD OF MAKIN THE SAME

-Willard .T. Case, New Brunswick, N. 1., assignor to Deltox Bug Company, Oshkosh, Wis., a corporation of Wisconsin Application March 27, 1944, Serial No. 528,251

5 Claims.

This invention relates to improvements in rugs and the method of making the same.

The present invention is directed to that type of rugs or coverings wherein a pile surface is produced on a fabric by the formation of lines of stitching wherein series of parallel lines of pile-forming stitching are traversed by other series of parallel lines of pile-forming stitching; and a general object of the present invention is to provide a rug wherein one series of stitching is of a .type to produce pile lines or areas different in character from that of another series of stitching with the result that the pile surface of the covering has a distinctive, attractive appearance, can be produced expeditiously, and is very durable.

A further object of the invention is to provide a tufted me having emphasized pattern or design areas therein which stand out from the background notwithstanding the fact that the piles may all be of the same color yarn.

A further object of the invention is to pro- -vide a. tufted rug wherein certain lines of stitching are loop producing and other lines of stitching aretuft producing, the latter being sewed over the former and serving to prevent the lines of loop stitching from'pulling out of the fabric and also presenting on the pile surface of the rug a novel design effect and contrasting appearance.

A further object of the invention is to provide a tufted rug wherein a substantial portion of the piles are formed of loop stitches which are very durable, create a. heavy, soft pile, and- .ing of parallel rows of tuft forming stitches between the traversi'ng rows of loop stitches, the tuft forming stitches being over the loop stitches and serving to prevent the same from pulling out of th fabric, and therows of tufts 'on the pile .surface of the rug, because of their spreading character, predominating at the intersection of rows.

A further object of the invention is to provide a tufted rug or covering and method of making the same which is simple, inexpensive and expeditious,, commercially practical, and well adapted for the purposes described.-

With the above and other objects in view the invention consists of the improved rug and method of making the same, and. its parts, combinations, and steps as set forth in the claims,- and all equivalentsthereof. v

In the accompanying drawing in which the same reference characters indicate the same parts in all of the views:

Fig. 1 is a fragmentary plan view of the outer side of a, portion of a rug or covering embodying the invention;

Fig. 2 is a fragmentary plan view of the reverse or rear side of the rug shown in Fig. 1; and

Fig. 3 is an enlarged, transverse vertical sectional view taken on line 3-3 of Fig. 1.

Referring now more particularly to the drawing it will appear that the backing of the 118 is indicated by the numeral 5. Said backing is formed of canvas, or a similar suitable fabric, and may be of any number of plies. One surface of the backing originally has stencilled thereonguide lines for the subsequent sewing operations. For the major portion of the rug or covering the guide lines for the present improvements comprise a series of spaced parallel lines extending -in one direction traversed by another'series of spaced parallel lines at right anglesto the lines of the first series. The size and contour of the backing is variable, according to what is desired in this respect for the finished article.

In carrying out the method of the present invention and subject to variations in detail, a series of diagonal alternate rows of machine produced loop stitching 6 are applied along'selected guide lines on the backing 5. These rowsare doubly spaced and the application of the same is then followed by doubly spaced rows of loop stitching I. which traverse or cross, preferably at right angles, the rows or lines of stitching 6 first applied. On the top'or outer side of the backing these lines of cross stitching provide projecting pile loops which break through, interrupt and intermingle with theloops of the first sewedrows at the various points of intersection. Thereafter, the sewing is applied in the first direction and lines of tuft forming stitching 8 in'doubly spaced, parallel rows are produced between the first rows 6. The tuft forming rows 8 intersect the cross loop rows 1 and on the front side of the backing, because of the spreading, bushy character of the tuft stitches thesame predominate and spread over and about the loop stitches. The last operation is the sewing of doubly spaced, parallel rows of cross tuft stitches 9 which are applied between the cross rows of loop stitching I and therefore intersect both the loop stitching rows l and the tuft stitching rows 8. As both series of rows of tuft forming stitching are applied after both series of rows of loop-forming stitching, the former cover the latter on the bottom side of the backing. as will appear from Fig. 2, and prevent the loop stitches from pulling out.

The effect of the pile surface of the rug is as depicted in Fig. 1 with the tuft stitches predominating and spreading and matting over and about the loop piles. A definite design configuration or pattern is thereby produced which is variable according to the manner of applying the rows of stitching, the spacing thereof, and other factors. Also, the tuft stitches may be longer than the loop stitches, or vice versa, or both may be of the same length.

Intermingling loop and tuft stitching to form the pile surface of a rug or covering has decided advantages additional to the novel appearance obtained. Loop stitching can be performed much more expeditiously than tuft stitches (the latter requiring a cutting operation) and this makes the rug faster and cheaper to produce than one whose pile surface is entirely of tuft stitches. Also, the loop-stitches have more thickness and durability than do the tuft stitches and do not fray. The tuft stitches, however, give the rug a soft and thick piled appearance and feel, and the same, by spreading and bunching, very adequately cover the backing surface between the rows of stitching.

Obviously, within the contemplation of the present invention the same color yarn may be used for all of the rows of stitching or the loop stitching rows and the tuft stitching rows may be of contrasting colors. Often variations are also possible. The description given applies only to the making of the body portion of a rug or covering. Bordering can be done in any of the conventional manners or by associating outlines of loop stitching with outlines of tuft stitching.

The invention is applicable, not only to rugs. but to seat covers, bath mats and other forms of piled surfaced coverings. Wherever the term rug is used herein and in the claims it is intended to comprehend all such articles.

From the foregoing description it will be seen that the improved rug and method of making the same is simple, expeditious, inexpensive, commercially practical, and well adapted for the pur poses set forth.

What is claimed as the invention'is:

1. The method of making a pile covering which comprises, first running a series of rows of substantially parallel loop producing stitching through a base fabric in a predetermined direction, spacing said rows from one another a multiple of the intended distance between rows in the completed covering, next running a second series of rows of substantially parallel loop producing stitchin of like character transversely through the rows of the first series, next running a series of rows of tuft producing stitching parallel with the rows of the first series and'in intervening relation thereto, and finally running a serie of rows of tuft producing stitching parallel with the rows of the second series and in intervening relation thereto.

2. The method of making a pile covering which comprises, first running a series of rows of substantially parallel loop producing stitching through a base fabric in a predetermined direction, spacing said rows from one another a multiple of the intended distance between rows in the completed covering, next runnin a.-second series of rows of substantially parallel loop producing stitching of like character transversely through the rows of the first series, next running a series of rows of tuft producing stitching parallel with the rows of the first series and in intervening relation thereto, and finally running a series of rows of tuft producing stitching parallel with the rows of the second series and in intervening relation thereto, each series of rows of tuft producing stitching extending over a series of rows of loop producing stitching on the reverse side of the base fabric anchoring the loopstitching thereto and preventing the same from pulling out.

3. The method of making a pile covering which comprises, the running of rows of substantially parallel loop stitching through a base fabric in'a predetermined direction, each stitch affording an upstanding loop, then running parallel rows of loop stitching of like character transversely through the first mentioned rows, the loops of one series densely intermingling with the loops of the other series at the points of intersection, and thereafter running rows of substantially parallel tuft stitching between all of the rows of loop stitching, each of the last mentioned stitches affording an upstanding outwardly spreading cut tuft, the spacing observed between rows of stitching being such as to spread the tips of the tufts throughout the covering to contact one another to conceal the base fabric and spread over and intermingle with the loops, the individual tufts at the points of intersection of rows of tuft stitches with crossing rows of tuft stitches being more densely crowded together to form contiguous group-tufts affording a characteristic texture and appearance in the completed covering.

4. A tufted rug, comprising a base fabric carrying two series of crossing rows of loop stitching, each stitch affording an upstanding loop, the individual loops at the points of intersection of the rows of stitching being more densely crowded together and reinforcing one another against matting down and forming predominate contiguous group-loops, and two series of crossing rows of tuft stitching, the rows of each of said series being between the rows of a series of loop stitching, each tuft stitch affording an upwardly extending outwardly spreading out tuft, the spacing of all of the rows of stitching being such as to cause the tufts and loops to contact and reinforce one anothe and the tufts to spread and conceal the base fabric, the individual tufts at the points of intersection of rows of tuft stitching being 'densely crowded together and forming predominate contiguous group tufts which spread over adjacent loops, the lines of tuft stitching relative to the underside of the base fabric being over the lines of loop stitching to secure the loop stitching thereto against pulling out.

5. A tufted rug, comprising a base fabric carrying a first series of rows of substantially parallel loop stitching running in a predetermined direction, each stitch affording an upstanding loop and said rows being spaced from one another a multiple of the intended distance between rows in the completed rug, the base fabric carrying a' second series of parallel rows of loop stitching of like character running transversely through the a,seo,sos I 3 rows of the first series and commingling with the loops of said first series at the points of intersection and affording design areas in the completed rug, and the-base fabric. carrying a third series of parallel rows of tuft stitching running parallel with the'rows of the first series and in intervening relation thereto and traversing the loops of the second series, and the base fabric carrying a fourth series of parallel rows of tuft stitching of like. character running parallel with the rows of the second series and in intervening relation thereto and intersecting and displacing the tufts of the third series, the spacing observed in the stitching being such as to cause the spread tips of the tufts throughout the rug to contact one another to conceal the base fabric and afford with the loops a pile surface, and the individual tufts at the points of intersection of the rows of tuft stitches being more densely crowded together to reinforce one another against matting down and form contiguous group tufts affording a m characteristic appearance in the completed rug.

WILLARD 1. CASE 

